Case Study
Arbroath Malting Plant
Project:
Malting Plant
Client: Bairds Malt
History: Bairds Malt operates five malting plants throughout the UK, producing 250,000 metric tonnes of malt annually for beer and whiskey production. To meet increasing demand, they expanded their capacity by constructing a new malting plant in Arbroath.
"Silchester's comprehensive support and advanced control system design were crucial in the successful expansion of our malting capacity at Arbroath."
- Client Representative
Solution
The main plant was supplied by Buhler, with Silchester providing comprehensive services, including:
- Electrical Distribution design & build
- Electrical MCC Panel design & build
- Control Panel design & build
- Control System design & build
- Network Infrastructure design
- Installation support
- Commissioning support
- 24-hour remote system support
The control system was designed around the following equipment:
- 4 Schneider Quantum PLCs
- 4 Schneider XBT HMIs
- 2 Wonderware Intouch SCADA systems with Batch, Recipe & Reporting
- 5 Remote IO Panels housing Advantys I/O (Profibus & Ethernet)
- 3 distribution panels for Kiln, Steeps & Germination systems
- 8 combined MCC / Control panels
- ABB VSDs (7.5 to 450kW)
- SEW VSDs (0.75 to 37kW)
- Telemecanique Softstarts (55kW)
Two types of communication networks were utilised:
- Ethernet – Fibre: Provided the communication backbone between process buildings, control room, and offices.
- Ethernet - Copper: Used for inter-PLC communications, remote IO, HMI & SCADA communications.
- Profibus: Used for remote I/O communications through slip rings onto rotating machinery.
Results
The new Arbroath malting plant successfully increased Bairds Malt's production capacity, allowing the company to meet the increasing demand for malt in beer and whiskey production. Equipped with advanced control systems and a robust network infrastructure, the plant ensures efficient, reliable, and scalable operations.
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